Aerosol generating material

ABSTRACT

The invention relates to an aerosol generating material comprising cut tobacco material and cut plant material, the cut plant material having an average particle size of at least about 0.25 mm. The invention further relates to non-combustible aerosol provision systems and consumables comprising the aerosol generating material, as well as to methods for preparing the aerosol generating material.

PRIORITY CLAIM

The present application is a National Phase entry of PCT Application No.PCT/GB2021/053267, filed Dec. 13, 2021, which claims priority from GBApplication No. 2019625.9, filed Dec. 11, 2020, each of which is herebyfully incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to an aerosol generating materialcomprising tobacco material and particles of plant material.

BACKGROUND

Aerosol-generating materials for use in a combustible or anon-combustible aerosol provision system may include a variety ofdifferent active substances and/or flavors and a user selectsaerosol-generating material to provide the desired user experience.

The inclusion of clove material into conventional combustible cigarettesis known in the art that and is commonly known as kretek. A factory madekretek cigarette has several features which can impact the organolepticproperties of the aerosol generated. It may include a sweetened tipping,which can amplify and balance the taste, the casing and flavor add aunique, sweet and spicy flavor. The tobacco comprises chopped “Rajangan”tobacco which also adds to the distinctive taste of these products. Avariety of types of tobacco may be included in the kretek cigarette, forexample, “dark Rajangan” tobacco has a complex taste, compared to“bright Rajangan” tobacco which is known for its' lighter taste. The cutclove found in these cigarettes contributes to a spicy, aromatic numbingand crackling flavor. These smoking articles may contain additionalflavor components.

SUMMARY

In accordance with a first aspect of the invention described herein,there is provided an aerosol generating material comprising cut tobaccomaterial and cut plant material, the cut plant material having anaverage particle size of at least about 0.25 mm.

In some embodiments, the cut plant material has an average particle sizeof from about 0.3 mm to about 0.5 mm.

In some embodiments, the cut plant material comprises clove.

In some embodiments, the cut tobacco material comprises reconstitutedtobacco.

In some embodiments, comprising from about 25% to about 40% by weight ofcut plant material based upon the weight of the aerosol generatingmaterial.

In some embodiments, the density of the aerosol generating material isfrom about 0.25 to about 0.45 g/cm³, and optionally from about 0.3 toabout 0.4 g/cm³.

In some embodiments, the cut tobacco material has a cut size of from 20to 25 CPI (cuts per inch), or from about 7.9 to about 9.8 cuts per cm.

In some embodiments, the aerosol generating material has a water contentof from about 8 to about 9%.

In some embodiments, the cut plant material is not immobilised withinthe aerosol generating material.

In some embodiments, the cut plant material is not incorporated intotobacco material.

In some embodiments, the aerosol generating material does not include abinder to bond the cut tobacco material and cut plant material.

According to a second aspect of the invention, there is provided anon-combustible aerosol provision system comprising an aerosolgenerating material according to the first embodiment.

In some embodiments, the system is an aerosol generating materialheating system comprising an aerosol generating material which is to beheated to volatilise constituents, and optionally including a filter orfilter element.

In some embodiments, the system is a hybrid system comprising an aerosolgenerating material which is to be heated to volatilise constituents,and a liquid which is to be heated to form a vapor, and optionallyincluding a filter or filter element.

In some embodiments, the aerosol generating material is heated by thevapor.

In some embodiments, the liquid is a nicotine-free liquid.

In some embodiments, the system includes a means for heating the liquidto form a vapor, but does not include a separate means for heating theaerosol generating material.

According to a third aspect of the present invention, there is provideda consumable comprising an aerosol generating material according to thefirst aspect.

In some embodiments, the consumable comprises a cartridge or podcomprising the aerosol generating material.

In some embodiments, the consumable comprises a rod or stick comprisingthe aerosol generating material.

According to a fourth aspect of the invention, there is provided amethod of preparing an aerosol generating material according to thefirst aspect, comprising combining cut tobacco material and cut plantmaterial.

In some embodiments, the consumable comprises the cut tobacco materialand cut plant material are combined by simple blending.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of exampleonly, with reference to accompanying drawing, in which

FIG. 1 is a flow chart showing key steps of a process according toembodiments of the present invention;

FIG. 2 is a schematic cross-sectional view of a product for heatingaerosol generating material to volatilise at least one component of theaerosol generating material; and

FIG. 3 is a schematic view of a hybrid system for heating aerosolgenerating material to volatilise at least one component of the aerosolgenerating material.

DETAILED DESCRIPTION

The aerosol-generating material described herein is to be used togenerate an aerosol with distinctive flavor and qualities to be inhaledby the end user. One of the aims of this invention is provide the enduser with an experience of using a non-combustible aerosol provisionsystem that is distinctive as a result of the inclusion of the plantmaterial. The impact of the plant material is influenced by the form inwhich it is included in the aerosol generating material and how thataffects the aerosol generated.

In embodiments where the plant material is clove, the aerosol generatingmaterial provides an aerosol generated by a non-combustible aerosolprovision system that is more closely aligned with the experience ofconsuming a combustible kretek cigarette.

The present invention relates to an aerosol generating materialcomprising a cut tobacco material and a cut plant material. The aerosolgenerating material may be used in a non-combustible aerosol provisionsystem, for example by incorporation into a consumable. The cut plantmaterial has an average particle size of at least about 250 μm, andoptionally up to about 500 μm or from about 280 μm to about 450 μm.

Particles of these dimensions have been found to provide sensoryproperties to the generated aerosol that differ to those provided byfiner plant particles (such as what is sometimes referred to as “dust”).For example, when the plant material is clove, the sensory properties ofthe aerosol are more like the distinctive taste characteristic of cloveand kretek cigarettes.

The inclusion of cut plant material with this larger particle size alsomeans that it is easier to incorporate a large proportion of plantmaterial into the aerosol generating material. For example, in someembodiments, the aerosol generating material comprises as much as about35% by weight plant material. If the plant particles were very fine,this could require the particles to be immobilised within the aerosolgenerating material to prevent the plant material being lost or movingrelative to the cut tobacco material so that the materials are nouniformly or homogenously mixed.

The presence of such a high proportion of fine plant particles wouldalso increase the density of the aerosol generating material within thenon-combustible aerosol provision system or consumable and could make itharder for an air flow, aerosol or vapor to pass through it, or for allof the aerosol generating material to be uniformly exposed to heat togenerate an aerosol. As a rule, the smaller the particle size, thegreater the surface area and therefor the greater the flavour delivery.However, smaller particle size can lead to processing difficulties andit can be harder to retain the particles within the aerosol generatingmaterial and/or consumable or non-combustible aerosol provision system.

The invention enjoys advantages such as improved flavor of the aerosolgenerated by the aerosol generating material by combining a cutbotanical material with a cut tobacco material. The size of the cutbotanical material has several advantages detailed herein.

The aerosol-generating material is a material that is capable ofgenerating aerosol, for example when heated, irradiated or energized inany other way. Aerosol-generating material may, for example, compriseone or more active substances and/or flavors, one or more aerosol-formermaterials, and optionally one or more other functional material.

The aerosol-former material may comprise one or more constituentscapable of forming an aerosol. In some embodiments, the aerosol-formermaterial may comprise one or more of glycerine, glycerol, propyleneglycol, diethylene glycol, triethylene glycol, tetraethylene glycol,1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyllaurate, a diethyl suberate, triethyl citrate, triacetin, a diacetinmixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, laurylacetate, lauric acid, myristic acid, and propylene carbonate.

The one or more other functional materials may comprise one or more ofpH regulators, colouring agents, preservatives, binders, fillers,stabilizers, and/or antioxidants.

In some embodiments, the aerosol generating material is a simple mixtureor blend of the cut tobacco material and the cut plant material.

The Plant Material

As used herein, the cut plant material may be clove or other materialderived from a plant.

As noted herein, the cut plant material may be derived from any materialderived from plants including, but not limited to, leaves, bark, fibres,stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like.The material may be in the form of particles, granules, pellets, shreds,strips, sheets, or the like. Example plants or botanicals are tobacco,Eucalyptus, star anise, hemp, cocoa, Cannabis, fennel, lemongrass,peppermint, spearmint, rooibos, chamomile, flax, ginger, Ginkgo biloba,hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orangeskin, Papaya, rose, sage, tea such as green tea or black tea, thyme,clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom,coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender,lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteakplant, Curcuma, turmeric, sandalwood, cilantro, bergamot, orangeblossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram,olive, lemon balm, lemon basil, chive, Carvi, Verbena, tarragon,geranium, mulberry, Ginseng, theanine, theacrine, maca, ashwagandha,damiana, guarana, chlorophyll, baobab or any combination thereof. Themint may be chosen from the following mint varieties: Mentha Arventis,Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citratac.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia,Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Menthaspicata c.v. and Mentha suaveolens.

In some embodiments, the cut plant material is clove. The use of clovesas the cut plant material provides a distinctive flavor and sensorialexperience for the end user. Cloves are known to have sensory effectsincluding aroma, spicy, numbing, crackling, and throat soothing featuresamong others. The organoleptic properties of the inhaled medium isthereby improved, and this can also be achieved without changing thedimensions of the non-combustible aerosol provision system.

The use of cloves in combustible cigarettes also has a historicprecedent in some regions, known as a “kretek” cigarette. The inventionprovides the user with the experience of a kretek cigarette withnon-combustible aerosol generating devices. The use of cloves thereforeadd value to a traditionally tobacco flavored non-combustible aerosolgenerating devices. In some embodiments, the aerosol generated hasflavours that are reminiscent of kretek cigarettes, which isadvantageous as this flavor is particularly popular with consumers incertain regions, for example Indonesia. Cloves contain several essentialoils, for example eugenol, which is known to provide some of thecharacteristic taste of the clove and is considered to have an analgesiceffect in traditional Chinese medicine.

The clove material may be derived from whole cloves or from parts ofwhole cloves, clove stalks, mother clove, blown cloves and/or exhaustedcloves as well as other clove derivatives that are known in the art or amixture of these.

In some embodiments, the plant material is cut into particles. Forexample, the plant material may be cut using any suitable process.

In some embodiments, the preparation of the cut plant (e.g. clove)particles involves the following steps:

-   -   1) Conditioning the plant material with water, steam and        temperature, to increase the moisture content from 10% to about        30%.    -   2) Cutting the plant material, for example using a machine with        rotatory knives, where the rate at which the plant material is        fed into the machine and the speed of the rotary cutting        controls the cut length.    -   3) The particle size of the cut plant material may be determined        by off line testing (sieving).

In some embodiments, the plant particle size may range from about 0.2 to0.5 mm, 0.25 to 0.4 mm, or 0.3 to 0.5 mm, or from about 0.25 to about0.45 mm.

In some embodiments, the plant material is cut to a size of 60-90 CPI(cuts per inch) or 23.6 to 35.4 cuts per cm, resulting in particles withan average size of from about 0.42 to about 0.28 mm.

The particle size can be measured in a variety of ways, such as laserdiffraction, microscopy, or preferentially by sieving. A common practiceis to give cut material a “mesh value”, which reflects the ability ofmore than 95% of the particles of a given particle population to passthrough a screen of a given mesh value. In that connection, mesh valuesreflect the number of mesh holes for each inch of screen. This methodselects particles of the desired size without the requirement to measuremultiple particles and measure an average distribution. Additionally,this may be used to measure the size of particles which do not have aregular spherical shape, making mean measurements challenging.

The size of the cut plant material particles is important and has aneffect on a number of features of the blend, such as improved mixing ofthe blend components and flavor release/delivery. The particle size isselected to deliver a suitable sensory effect, and the clove is selectedto deliver a characteristic taste. Without wishing to be bound by anyone particular theory, it is speculated that the chopping of the plantmaterial to form the cut plant material particles enhances the releaseof flavor constituents including volatile flavors and aromaticconstituents. The increased surface area of the tobacco particles isalso thought to aid volatilisation, as described herein.

Particle size is important as this alters the surface area to volumeratio of the particles. Without wishing to be bound by theory, it isproposed that larger particles with lower surface area to volume ratioshave a lower exposure to the air, and this reduces evaporation ofvolatile compounds that contribute to the distinctive flavor of theaerosol generated. Larger particles are easier to handle, may be storedfor longer and there is less release of volatile compounds prior tointentional heating by the end user.

A smaller particle size of the cut plant material is associated withlower particle size distribution and fill value. This makes the materialeasier to spread throughout an aerosol generating material uniformly.This provides a consistent taste for the end user throughout usage ofthe aerosol generating material.

On the other hand, a larger particle size of the cut plant material maybe associated with a different sensorial experience, and the particlesmust be large enough to for the volatiles to escape upon heating withoutbeing too densely packed to impede this.

Larger particles are easier to handle, and remain substantially dry,without substantial destruction of the cell structure. Lesssophisticated machinery can be used and this may be more economical tomanufacture. As less grounding is required, this is less energyintensive, and save energy and time in the manufacturing process.

Plant material particles of the desired size may be formed by grinding,shredding, cutting or crushing the plant material. Suitable machinery tocreate such plant particles includes, for example, shredders, cutters,or mills, such as hammer mills, roller mills or other types ofcommercially available milling machinery. The size of the plantparticles is selected to provide particles which can be readily preparedfrom a variety of different types of plant material including cloves andhaving the properties described herein, and which provide a source ofvolatile compounds that are readily released.

According to some embodiments, the plant material, is prepared along thefollowing lines. First, the plant material is conditioned to adjust(increase) the water content, for example to within the range of about32% to about 36%. This may be done whilst exposing the plant material toa temperature of from about 60 to about 70° C. and to water and steam.The plant material may then undergo a bulking step, for example for aperiod of 2 hours, to ensure that the water applied during theconditioning step is well absorbed by the plant material. Followingbulking, the plant material may be ready to be cut to the desiredparticle size. Thereafter, the cut plant material may undergo a dryingstep to adjust (reduce) the water content, for example to within therange of about 11% to about 12%. This may be done whilst exposing theplant material to a temperature of from about 45 to about 55° C.

The Tobacco

The tobacco material used to form the cut tobacco material may be anytype of tobacco and any part of the tobacco plant, including tobaccolamina, stem, stalk, ribs, scraps and shorts or mixtures of two or morethereof. Suitable tobacco materials include the following types: darktobacco, light tobacco, Rajangan tobacco, Virginia or flue-curedtobacco, Burley tobacco, Oriental tobacco, or blends of tobaccomaterials, optionally including those listed here. Some of these tobaccovarieties, such as Rajangan tobacco, may be processed differently, asknown to the skilled person.

The tobacco may be expanded, such as dry-ice expanded tobacco (DIET), orprocessed by any other means. In some embodiments, the tobacco materialmay be reconstituted tobacco material. The tobacco may be pre-processedor unprocessed, and may be, for instance, solid stems (SS); shreddeddried stems (SDS); steam treated stems (STS); or any combinationthereof. The tobacco material may be fermented, cured, uncured, toasted,or otherwise pre-treated.

In some embodiments, the tobacco material is in the form ofreconstituted tobacco that has been processed and cut to form a cut ragtobacco.

In some embodiments, the tobacco material is in the form of tobaccoparticles.

In some embodiments, the tobacco material may undergo treatment steps inorder to improve its properties for inclusion in an aerosol generatingmaterial. Illustrative steps are shown in the flow chart of FIG. 1 .

In some embodiments, the tobacco material has been conditioned. Forexample, this may involve adjusting the water content of the startingtobacco material to 20-22%. In some embodiments, casing may be added tothe tobacco material, for example in a ratio of 1.8 to 18% by weight.

The tobacco material may also, in some embodiments, undergoing a bulkingstep.

Following any such pre-treatment steps, the tobacco material is cut. Insome embodiments, the cut size is selected to ensure that the cuttobacco material and the cut plant material have particle sizes thatproduce a blend with desirable properties, as discussed herein. In someembodiments, the tobacco material is cut to a size of 20-25 CPI (cutsper inch) or from about 7.9 to about 9.8 cuts per cm, resulting instrips with an average width of 1 to 1.5 mm.

In some embodiments, the cut tobacco is dried. For example, the dryingof the tobacco may reduce the water content to about 7 to 8%.

In some embodiments, one or more flavors may be added to the tobaccomaterial. This may be done at any stage of the tobacco processing. Insome embodiments, the flavor is added after the tobacco material is cutand after any further drying step.

In some embodiments, a flavor is added to the tobacco material in anamount of from about 1% to about 3%, or from about 1 to about 2% byweight.

As used herein, the terms “flavor” and “flavorant” refer to materialswhich, where local regulations permit, may be used to create a desiredtaste, aroma or other somatosensorial sensation in a product for adultconsumers. They may include naturally occurring flavor materials,botanicals, extracts of botanicals, synthetically obtained materials, orcombinations thereof (e.g., tobacco, Cannabis, licorice (liquorice),Hydrangea, eugenol, Japanese white bark Magnolia leaf, chamomile,fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed(anise), cinnamon, turmeric, Indian spices, Asian spices, herb,wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange,mango, clementine, lemon, lime, tropical fruit, Papaya, rhubarb, grape,durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits,Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint,peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg,sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honeyessence, rose oil, vanilla, lemon oil, orange oil, orange blossom,cherry blossom, Cassia, caraway, cognac, jasmine, ylang-ylang, sage,fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil fromany species of the genus Mentha, Eucalyptus, star anise, cocoa,lemongrass, rooibos, flax, Ginkgo biloba, hazel, hibiscus, laurel, mate,orange skin, rose, tea such as green tea or black tea, thyme, juniper,elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary,saffron, lemon peel, mint, beefsteak plant, Curcuma, cilantro, myrtle,cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm,lemon basil, chive, Carvi, Verbena, tarragon, limonene, thymol,camphene), flavor enhancers, bitterness receptor site blockers,sensorial receptor site activators or stimulators, sugars and/or sugarsubstitutes (e.g., sucralose, acesulfame potassium, aspartame,saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol,or mannitol), and other additives such as charcoal, chlorophyll,minerals, botanicals, or breath freshening agents. They may beimitation, synthetic or natural ingredients or blends thereof. They maybe in any suitable form, for example, liquid such as an oil, solid suchas a powder, or gas.

In some embodiments, the flavor comprises menthol, spearmint and/orpeppermint. In some embodiments, the flavor comprises flavor componentsof cucumber, blueberry, citrus fruits and/or redberry. In someembodiments, the flavor comprises eugenol. In some embodiments, theflavor comprises flavour components extracted from tobacco. In someembodiments, the flavor comprises flavor components extracted fromCannabis.

In some embodiments, the flavor may comprise a sensate, which isintended to achieve a somatosensorial sensation which are usuallychemically induced and perceived by the stimulation of the fifth cranialnerve (trigeminal nerve), in addition to or in place of aroma or tastenerves, and these may include agents providing heating, cooling,tingling, numbing effect.

A suitable heat effect agent may be, but is not limited to, vanillylethyl ether and a suitable cooling agent may be, but not limited toeucolyptol, WS-3.

In some embodiments, flavors are included that provide the aerosolgenerated by the aerosol-generating material with aroma and tastereminiscent of a kretek product. In some embodiments, flavors maybe beadded to emphasize certain flavor notes or sensual effects associatedwith a kretek product. In some embodiments of the invention, this flavoris eugenol.

In some embodiments, flavors are included to generate extra connotationsof sweetness and fruits and/or tropical notes.

The Mixture of Plant Material and Tobacco Material

The aerosol generating material may be prepared by simple mixing of oneor more cut plant materials and one or more cut tobacco materials. Themixing may involve blending of the cut materials, for example, usingconventional mixing or blending techniques used to mix or blend cuttobacco material. Alternatively, the cut plant material may be addedover the cut tobacco.

In some embodiments, the cut plant material is in the form of afree-flowing solid when it is mixed or blended with the cut tobaccomaterial.

In some embodiments, no binder is used when the tobacco and cut plantmaterial, such as clove, is mixed.

The mixing can take place, for example, in a rotatory cylinder mixer,with the selection of appropriate process parameters including: cylinderlength, inclination of the cylinder, and residence time. Generally, thelonger the residence time, the greater the mixing of the materials.

In some embodiments, the particles of the cut tobacco material and thecut botanical material are differently sized. In some embodiments, theparticles of the cut tobacco material and the cut botanical material arethe same size. The choice of size depends on several factors, such astaste and mouth-feel of the generated aerosol, packed density of theaerosol generating material and other factors known to the personskilled in the art.

The amount of the cut plant material included in the aerosol generatingmaterial and the ratio of plant material to cut tobacco material canvary in different embodiments. For example, in some embodiments, astronger clove flavor can be provided with a higher proportion of clovematerial. This applies to other plant materials and flavors. On theother hand, increasing the tobacco proportion in the aerosol generatingmaterial may increase the tobacco flavor and/or nicotine content in theaerosol generated. The proportion of ingredients can also affect themouth-feel and texture of the aerosol.

The selection of the amount of plant material to include in the aerosolgenerating material will be based upon sensorial considerations. The aimis add the flavor and aroma of the plant material and to do so inappropriate balance with the delivery of tobacco flavors and aromas. Itmay also be a consideration that the flavor delivery should last for theentirety of the period of use of the aerosol generating material

In some embodiments, including embodiments where the plant material isclove, at least 15% by weight of the aerosol generating material isplant material. The upper limit may be about 35% by weight of theaerosol generating material being the plant material.

Varying the proportion of the components can also change the density ofthe aerosol generating material and the amount that may be packed into acontainer or consumable of given dimensions. An additional factor totake into consideration is the price of the component materials. Theblend can be formulated to provide a cost effective product. Theinclusion of a higher proportion of cloves can help with mixing betweenthe clove material and the tobacco material.

In some embodiments, the blend of cut tobacco material and cut plantmaterial includes at least about 5% by weight or volume of the cut plantmaterial and may include between about 25% to about 40% by weight orvolume of the cut plant material. In some embodiments, the weight and/orvolume of the clove component with respect to the tobacco materialcomponent is about 25%. In some embodiments, the blend of cut tobaccomaterial and cut plant material includes 5, 10, 15, 20, 25, 30, 35, 40or 45% by weight or volume.

In some embodiments, the aerosol generating material further comprises adiluent. The diluent may be in solid or liquid form. In someembodiments, the diluent is inert or substantially inert.

In some embodiments, the aerosol generating material further comprisesat least one aerosol forming agent which may be, for instance, a polyolaerosol generator or a non-polyol aerosol generator, preferably anon-polyol aerosol generator. It may be a solid or liquid at roomtemperature, but preferably is a liquid at room temperature. Suitablepolyols include sorbitol, glycerol, and glycols like propylene glycol ortriethylene glycol. Suitable non-polyols include monohydric alcohols,high boiling point hydrocarbons, acids such as lactic acid, and esterssuch as diacetin, triacetin, triethyl citrate or isopropyl myristate. Acombination of aerosol forming agents may be used, in equal or differingproportions. Glycerol and propylene glycol may be particularlypreferred.

In some embodiments, the aerosol generating material includes one ormore additional components, some of which may immobilise the cut plantmaterial and/or the cut tobacco material. The aerosol generatingmaterial or the tobacco material may comprise one or more bindingadditives. The binding additive helps to adhere particles of tobaccomaterial to each other and to other components in the aerosol generatingmaterial. Suitable binding additives include, for example,thermoreversible gelling agents such as gelatin, starches,polysaccharides, pectins, alginates, wood pulp, celluloses, andcellulose derivatives such as carboxymethylcellulose. Inclusion of abinding additive may have the advantage that the aerosol-generatingmaterial is easier to handle and process.

In some embodiments, the aerosol generating material does not include abinder, plasticizer or gelling agent. This reduces material costs andsimplifies manufacturing. Additionally, the inclusion of a binder may,for some plant materials such as clove, require modification of theplant material by either temperature treatment or by water/steamtreatment, which can remove some of the oils that generate the desiredsensorial effect.

In some embodiments, the aerosol generating material further comprises apreservative. Suitable preservatives would be readily known to theskilled person and would include, for example, those that are safe foruse in products producing inhalable aerosols. Examples of preservativesthat might be used include: propylene glycol, carvacrol, thymol,L-menthol, 1,8-cineole, phenoxyethanol, PhytoCide, sorbic acid and itssalts, sodium hydroxymethylglycinate, ethylhexylglycerin, parabens andvitamins such as vitamin E or vitamin C.

According to another aspect of the present invention, there is provideda non-combustible aerosol provision system including an aerosolgenerating material. The aerosol generating material included in theaerosol provision system may comprise, consist essentially of, orconsist of the aerosol generating material as described herein.

As used herein, an aerosol provision system includes non-combustibleaerosol provision systems that release compounds from an aerosolgenerating material without combusting the aerosol-generating material,such as tobacco heating products, and hybrid systems to generate aerosolusing a combination of aerosol-generating materials.

According to the present disclosure, a “non-combustible” aerosolprovision system is one where a constituent aerosol-generating materialof the aerosol provision system (or component thereof) is not combustedor burned in order to facilitate delivery of at least one substance to auser. In some embodiments, the delivery system is a non-combustibleaerosol provision system, such as a powered non-combustible aerosolprovision system.

In some embodiments, the non-combustible aerosol provision system is anelectronic cigarette, also known as a vaping device or electronicnicotine delivery system (END), although it is noted that the presenceof nicotine in the aerosol-generating material is not a requirement.

In some embodiments, the non-combustible aerosol provision system is anaerosol-generating material heating system, also known as aheat-not-burn system. An example of such a system is a tobacco heatingsystem.

In some embodiments, the non-combustible aerosol provision system is ahybrid system to generate aerosol using a combination ofaerosol-generating materials, one or a plurality of which may be heated.Each of the aerosol-generating materials may be, for example, in theform of a solid, liquid or gel and may or may not contain nicotine. Insome embodiments, the hybrid system comprises a liquid or gelaerosol-generating material and a solid aerosol-generating material. Thesolid aerosol-generating material may comprise, for example, tobacco ora non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise anon-combustible aerosol provision device and a consumable for use withthe non-combustible aerosol provision device.

In some embodiments, the disclosure relates to consumables comprisingaerosol-generating material and configured to be used withnon-combustible aerosol provision devices. These consumables aresometimes referred to as articles throughout the disclosure.

In some embodiments, the non-combustible aerosol provision system, suchas a non-combustible aerosol provision device thereof, may comprise apower source and a controller. The power source may, for example, be anelectric power source or an exothermic power source. In someembodiments, the exothermic power source comprises a carbon substratewhich may be energised so as to distribute power in the form of heat toan aerosol-generating material or to a heat transfer material inproximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system maycomprise an area for receiving the consumable, an aerosol generator, anaerosol generation area, a housing, a mouthpiece, a filter and/or anaerosol-modifying agent.

In some embodiments, the consumable for use with the non-combustibleaerosol provision device may comprise aerosol-generating material, anaerosol-generating material storage area, an aerosol-generating materialtransfer component, an aerosol generator, an aerosol generation area, ahousing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifyingagent.

According to some embodiments, the aerosol generating material isincluded in the aerosol provision system to volatilise components of theaerosol generating material by heating but not combusting the material(i.e., a tobacco heating product or so-called Heat-not-Burn product). Insome of these products, the aerosol generating material is heated togenerate an aerosol.

FIG. 2 shows a cross-sectional view of an example of a tobacco heatingproduct for heating an aerosol generating material. The apparatus 11 hasa heating chamber 14 which in use contains the aerosol generatingmaterial to be heated and volatilised. In this embodiment, the aerosolgenerating material is in the form of a monolithic nicotine deliverycomposition 13. The aerosol generating material could however bemultiple particles of aerosol generating material held in the heatingchamber or provided in a cartridge.

The apparatus 11 of FIG. 2 further has an electronics/power chamber 16which may, for example, contain electrical control circuitry and/or apower source (not shown). The electrical control circuitry may include acontroller, such as a microprocessor arrangement, configured andarranged to control the heating of the aerosol generating material via aheating element (not shown). The electrical control circuitry may in usereceive a signal from for example a puff-actuated sensor which issensitive to for example changes in pressure or changes in rate of airflow that occur upon initiation of a draw on the apparatus 11 by a user.The electrical control circuitry can then operate so as to cause heatingof the aerosol generating material “on demand”. Various arrangements fora puff-actuated sensor are available, including for example athermistor, an electro-mechanical device, a mechanical device, anoptical device, an opto-mechanical device and a micro electro mechanicalsystems (MEMS) based sensor. As an alternative, the apparatus may have amanually operable switch for a user to initiate a puff.

The heating chamber 14 is contained within the housing 12. There may bea support and/or insulating means (not shown) positioned between theheating chamber 14 and the housing 12, for example to assist inheat-insulating the housing 12 from the heating chamber 14, so that thehousing 12 does not become hot or at least too hot to touch during use.

The housing 12 includes an inlet 15 through which air is drawn into theapparatus. The housing 12 also includes an outlet 17 at a mouthpiece 18of the apparatus 11. Air is drawn into the apparatus 11 through theinlet 15, travels through the apparatus picking up the active substanceand other volatile constituents released by the aerosol generatingmaterial 13, and the resulting aerosol generated by the apparatus 11leaves the apparatus 11 through the outlet 19 and is inhaled by theuser.

According to some embodiments, the aerosol generating material isincluded in a so-called hybrid system for heating aerosol generatingmaterial to volatilise at least one component of an aerosol generatingmaterial. In some of these products, the aerosol generating material isheated to generate an aerosol, in addition to the heating of a liquid,such as a nicotine-containing liquid or a nicotine-free liquid, which isheated by a heat source to form an aerosol or vapor. In some hybridsystems, the aerosol or vapor formed from the liquid is drawn over orthrough the aerosol generating material, picking up the activesubstance(s) and other volatilised components. In other embodiments, theaerosol or vapor formed from the liquid is not drawn over or through theaerosol generating material.

FIG. 3 shows a cross-sectional view of an example of a hybrid productfor heating an aerosol generating material and a liquid. The apparatus21 has a housing 22 containing a chamber 24 which in use contains theaerosol generating material 23 to be heated and volatilised. The aerosolgenerating material could be held in the chamber or provided in acartridge. The housing 22 also contains a liquid reservoir 25 containinga liquid 26 to be heated to form a vapor.

The apparatus 21 further has an electronics/power chamber 27 which may,for example, contain electrical control circuitry and/or a power source(not shown). The electrical control circuitry may include a controller,such as a microprocessor arrangement, configured and arranged to controlthe heating of the aerosol generating material and of the liquid 26 viaone or more heating elements (not shown). The electrical controlcircuitry may allow the apparatus 21 to be puff-actuated, so as to causeheating of the aerosol generating material “on demand”. As analternative, the apparatus 22 may have a manually operable switch for auser to initiate a puff.

The housing 22 also includes an inlet 28 through which air is drawn intothe apparatus. The housing 22 also includes an outlet 29 at a mouthpiece30 of the apparatus 21. Air is drawn into the apparatus 21 through theinlet 28, travels through the apparatus picking up the vapor created byheating the liquid 26 in the liquid reservoir 25, and activesubstance(s) and volatile component released by the aerosol generatingmaterial 23, and the resulting aerosol generated by the apparatus 21leaves the apparatus 21 through the outlet 29 and is inhaled by theuser.

The hybrid device 21 shown schematically in FIG. 3 represents just onepossible configuration of such an apparatus. The relative positions ofthe liquid reservoir 25 and the aerosol generating material chamber 24can be changed, as can the path of the air flowing through theapparatus.

In one embodiment, the liquid reservoir is positioned upstream of theaerosol generating material to be volatilised. Alternatively, the liquidreservoir may be positioned downstream of the aerosol generatingmaterial to be volatilised. In a yet further arrangement, the twosources of aerosol in the apparatus may be arranged side-by-side, etc.

In some embodiments, the vapor produced by heating the liquid in theliquid reservoir flows over or through the aerosol generating materialcomprising or consisting of one or more aerosol generating material. Insome embodiments, the elevated temperature of the vapor causes theactive substance and volatile components to be released. Alternativelyor in addition, the aerosol generating material may be separately heatedby a heating means.

In some embodiments, a hybrid device is provided in which the vaporcreated by heating a liquid heats the aerosol generating material inorder to volatilise at least one component of the aerosol generatingmaterial. In some embodiments, the liquid is a nicotine-free liquid. Inother embodiments, the liquid contains nicotine. Where the aerosolgenerating material is heated by the vapor to volatilise at least onecomponent of the aerosol generating material, in certain embodiments thedevice does not include a separate means for heating the aerosolgenerating material.

In other embodiments, the vapor produced by heating the liquid in theliquid reservoir does not flows over or through the aerosol generatingmaterial. Rather, this vapor and the aerosol generated by heating theaerosol generating material only mix after they are both formed.

The tobacco heating products and hybrid products described herein may,in some embodiments, include aerosol generating material in the form ofcontainers or cartridges containing the aerosol generating material.These containers or cartridges may be removable. They may replace boththe chamber holding the aerosol generating material and the aerosolgenerating material in the apparatus described above with reference toFIGS. 2 and 3 , and in the alternative embodiments discussed.

Consumable

According to a third aspect of the invention a consumable for anon-combustible aerosol provision system is provided comprising theaerosol generating material including combining a cut plant material anda cut tobacco material.

A consumable is an article comprising or consisting ofaerosol-generating material, part or all of which is intended to beconsumed during use by a user. A consumable may comprise one or moreother components, such as an aerosol-generating material storage area,an aerosol-generating material transfer component, an aerosol generationarea, a housing, a wrapper, a mouthpiece, a filter and/or anaerosol-modifying agent. A consumable may also comprise an aerosolgenerator, such as a heater, that emits heat to cause theaerosol-generating material to generate aerosol in use. The heater may,for example, comprise combustible material, a material heatable byelectrical conduction, or a susceptor. The consumable may also containother non-tobacco products, which, depending on the product, may eithercontain nicotine or not contain it. It also may contain one or morehumectants, such as glycerin or propylene glycol.

In some embodiments, the consumable is a cartridge or pod containing theaerosol generating material. In other embodiments, the consumable may bein the form of a rod or stick containing the aerosol generatingmaterial. For example, the rod or stick may be circumscribed with awrapper. The rod or stick may comprise one or more additional sections,in addition to one or more sections comprising aerosol generatingmaterial. Such sections may include filtering sections, coolingsections, or sections with other materials that generate aerosol ormodify the aerosol, for example by adding flavor.

Method for Preparing the Aerosol-Generating Material

According to a fourth aspect of the invention, a method of preparing theaerosol-generating material described herein is provided.

In a generalised example, preparing the aerosol generating material mayinvolve the following steps.

The cut tobacco material may be prepared using a method including one ormore the following steps: selecting the tobacco material; conditioningand casing; bulking, cutting; drying; and flavoring.

The cut plant material may be prepared by a method including one or moreof the following steps: selecting the plant material; conditioning;bulking, cutting; and drying.

The cut tobacco material and cut plant material are then combined toform the aerosol generating material. The combination may be mixed orblended. Optionally, the aerosol generating material is incorporatedinto a consumable or into a non-combustible aerosol provision system.

The various embodiments described herein are presented only to assist inunderstanding and teaching the claimed features. These embodiments areprovided as a representative sample of embodiments only, and are notexhaustive and/or exclusive. It is to be understood that advantages,embodiments, examples, functions, features, structures, and/or otheraspects described herein are not to be considered limitations on thescope of the invention as defined by the claims or limitations onequivalents to the claims, and that other embodiments may be utilizedand modifications may be made without departing from the scope of theclaimed invention. Various embodiments of the invention may suitablycomprise, consist of, or consist essentially of, appropriatecombinations of the disclosed elements, components, features, parts,steps, means, etc., other than those specifically described herein. Inaddition, this disclosure may include other inventions not presentlyclaimed, but which may be claimed in future. The delivery systemdescribed herein can be implemented as a non-combustible aerosolprovision system.

1. An aerosol generating material comprising cut tobacco material andcut plant material, the cut plant material having an average particlesize of at least about 0.25 mm.
 2. An aerosol generating material asclaimed in claim 1, wherein the cut plant material has an averageparticle size of from about 0.3 mm to about 0.5 mm.
 3. An aerosolgenerating material as claimed in claim 1, wherein the cut plantmaterial comprises clove.
 4. An aerosol generating material as claimedin claim 1, wherein the cut tobacco material comprises reconstitutedtobacco.
 5. An aerosol generating material as claimed in claim 1,comprising from about 25% to about 40% by weight of cut plant materialbased upon the weight of the aerosol generating material.
 6. An aerosolgenerating material as claimed in claim 1, wherein the density of theaerosol generating material is from about 0.25 to about 0.45 g/cm³, andoptionally from about 0.3 to about 0.4 g/cm³.
 7. An aerosol generatingmaterial as claimed in claim 1, wherein the cut tobacco material has acut size of from 20 to 25 CPI (cuts per inch), or from about 7.9 toabout 9.8 cuts per cm.
 8. An aerosol generating material as claimed inclaim 1, having a water content of from about 8 to about 9%.
 9. Anaerosol generating material as claimed in claim 1, wherein the cut plantmaterial is not immobilised within the aerosol generating material. 10.An aerosol generating material as claimed in claim 9, wherein the cutplant material is not incorporated into tobacco material.
 11. An aerosolgenerating material as claimed claim 9, wherein the aerosol generatingmaterial does not include a binder to bond the cut tobacco material andcut plant material.
 12. A non-combustible aerosol provision systemcomprising the aerosol generating material of claim
 1. 13. A system asclaimed in claim 12, wherein the system is an aerosol generatingmaterial heating system comprising an aerosol generating material whichis to be heated to volatilise constituents, and optionally including afilter or filter element.
 14. A system as claimed in claim 12, whereinthe system is a hybrid system comprising an aerosol generating materialwhich is to be heated to volatilise constituents, and a liquid which isto be heated to form a vapour, and optionally including a filter orfilter element.
 15. A system as claimed in claim 14, wherein the aerosolgenerating material is heated by the vapour.
 16. A system as claimed inclaim 15, wherein the liquid is a nicotine-free liquid.
 17. A system asclaimed in claim 15, wherein the system includes a means for heating theliquid to form a vapour, but does not include a separate means forheating the aerosol generating material.
 18. A consumable comprising theaerosol generating material of claim
 1. 19. A consumable as claimed inclaim 18, comprising a cartridge or pod comprising the aerosolgenerating material.
 20. A consumable as claimed in claim 18, comprisinga rod or stick comprising the aerosol generating material.
 21. A methodof preparing the aerosol generating material of claim 1, comprisingcombining cut tobacco material and cut plant material.
 22. A method asclaimed in claim 21, wherein the cut tobacco material and cut plantmaterial are combined by simple blending.